Washing appliance and associated method

ABSTRACT

A washing appliance and associated method are provided. The appliance includes a tub having a bottom wall member with forward and rearward edges. A door member has a lower edge pivotably engaged with the forward edge. A base member supports the tub and extends from about the rearward edge of the bottom wall member toward the forward edge. The base member has a forward end disposed opposite the forward edge from the lower edge of the door member, to form a toe kick recess between the lower edge and the forward end. A cover member engages the forward end of the base member, and has a flange portion extending to the forward edge of the bottom wall member, for covering the forward end of the base member and the bottom wall member about the toe kick recess, while allowing the door member to pivot to provide access to the tub.

BACKGROUND OF THE INVENTION

1. Field of the Invention

Embodiments of the present invention relate to washing appliances and,more particularly, to a dishwasher and a method associated therewith.

2. Description of Related Art

Washing appliances, such as dishwashers, may include a wash tub forcontaining dishware or other items to be washed. However, the tub mustalso include surrounding structure and components to form an overallappliance assembly. Components of the appliance, such as the variouscontrols, valves, and pumps, for example, are mounted outside the tub,but within the overall structure of the appliance. Accordingly, in somewashing appliances, the tub is may be supported within the applianceassembly by a frame or other support structure, wherein the frame mustbe fastened or otherwise secured to the tub in order to maintain theappliance assembly. Many of the various operative components of theappliance may thus be mounted to the frame, under the tub, or in anysuitable location. As such, the typical washing appliance may notfacilitate ease of assembly of the appliance.

Some conventional washing appliances may include a front-opening door,hinged at the lower end thereof, for providing access to the interior ofthe tub. Such a hinged door may make it difficult to structure a frameor other support assembly for effectively enclosing the appliance, whilealso allowing for the pivoting configuration of the door. In suchinstances, a less-than-complete enclosure of the appliance, resultingopen space under the door, or between the lower end of the door and theframe, may allow sound/noise generated by the operative components to“escape” from the appliance and undesirably emit noise into theenvironment.

Thus, there exists a need for an apparatus and method for a washingappliance for reducing the overall noise associated with the washingappliance.

BRIEF SUMMARY OF THE INVENTION

The above and other needs are met by the present invention which,according to one aspect, provides a washing appliance, comprising a tubhaving a bottom wall member and defining a forward access opening,wherein the bottom wall member has a forward edge and a rearward edge. Adoor member has a lower edge pivotably engaged with the forward edge ofthe bottom wall member, and is configured to cooperate with the tub tocover the forward access opening. A base member is configured to supportthe tub and extends from about the rearward edge of the bottom wallmember toward the forward edge thereof. The base member has a forwardend disposed opposite the forward edge of the bottom wall member fromthe lower edge of the door member, so as to form a toe kick recessbetween the lower edge and the forward end. A cover member is configuredto operably engage the forward end of the base member, and has a flangeportion extending therefrom to the forward edge of the bottom wallmember. The cover member is configured to cooperate with the base memberand the bottom wall member so as to cover the forward end of the basemember and the bottom wall member about the toe kick recess whileallowing the door member to pivot to an open position so as to provideaccess to the tub through the forward access opening.

Another aspect provides a method of forming a washing appliance, whereinsuch a washing appliance includes a tub having a bottom wall member anddefining a forward access opening, with the bottom wall member having aforward edge and a rearward edge; a door member having a lower edgepivotably engaged with the forward edge of the bottom wall member, andbeing configured to cooperate with the tub to cover the forward accessopening; and a base member configured to support the tub and extendingfrom about the rearward edge of the bottom wall member toward theforward edge thereof, with the base member having a forward end disposedopposite the forward edge of the bottom wall member from the lower edgeof the door member, so as to form a toe kick recess between the loweredge and the forward end. Accordingly, such a method comprises engaginga cover member with the forward end of the base member such that aflange portion of the cover member extends therefrom to the forward edgeof the bottom wall member, wherein the cover member is configured tocooperate with the base member and the bottom wall member so as to coverthe forward end of the base member and the bottom wall member about thetoe kick recess while allowing the door member to pivot to an openposition so as to provide access to the tub through the forward accessopening.

Thus, the various aspects of the present invention provide advantages,as otherwise detailed herein, that may include, but are not limited to:providing a washing appliance assembly including a base member and tubthat are engaged with one another such that noise emissions fromoperative components disposed within the base member are reduced (i.e.,provide a quieter appliance).

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Having thus described various embodiments of the invention in generalterms, reference will now be made to the accompanying drawings, whichare not necessarily drawn to scale, and wherein:

FIG. 1 is a perspective view of a base member, according to oneembodiment of the present invention, configured to operably engage a tubof a washing appliance;

FIG. 2 is a partially-exploded perspective view of a washing appliance,according to one embodiment of the present invention, including a basemember disposed adjacent to a tub;

FIG. 3 is a perspective view of a washing appliance, according to oneembodiment of the present invention, including a tub operably engagedwith a base member, wherein the tub is operably engaged with the basemember such that the access opening defined by the tub is disposedtoward a forward end thereof;

FIG. 4 is an exploded perspective view of a cover member configured tooperably engage a base member of a washing appliance, according to oneembodiment of the present invention;

FIG. 5 is a perspective rear view of a cover member, according to oneembodiment of the present invention, configured to operably engage abase member of a washing appliance; and

FIG. 6 is an exploded perspective rear view of a cover member, accordingto one embodiment of the present invention, including an insulationelement engaged with the cover member.

DETAILED DESCRIPTION OF VARIOUS EMBODIMENTS OF THE INVENTION

Various embodiments of present inventions now will be described morefully hereinafter with reference to the accompanying drawings, in whichsome, but not all embodiments of the inventions are shown. Indeed, theseinventions may be embodied in many different forms and should not beconstrued as limited to the embodiments set forth herein; rather, theseembodiments are provided so that this disclosure will satisfy applicablelegal requirements. Like numbers refer to like elements throughout.

Although the various embodiments of the invention described herein aredirected to a washing appliance and method, such as involving adishwasher, it will be appreciated by one skilled in the art that theinvention is not so limited. For example, aspects of the washingappliance and method of the present invention can also be incorporatedinto other washing appliances (such as laundry washing machines, forexample). In one example, the apparatus embodiments of the presentinvention may comprise a “front load” laundry washing machine having atub operably engaged with an integrally-molded base member foroptimizing the space occupied by various operative components disposedtherein, such that the capacity of the tub could possibly be increased.Further, such an assembly may provide “enclosure” aspects that containthe sound/noise emitted from the operative components so as to reducethe overall noise emitted from the washing appliance during operation.

Referring to FIG. 3, one embodiment of the present invention provides awashing appliance 1, such as a dishwasher, comprising a tub 10 having abottom wall member 15 (such as a floor and/or bottom wall member asshown in FIG. 2, for example) extending between a forward edge and arearward edge with respect to an access opening 17 (such as a dooropening, for example, of a dishwasher or laundry washing machineassembly) defined by the tub 10. The washing appliance 1 furthercomprises a base member 20 configured to receive and support the tub 10,wherein the base member 20 and the bottom wall member 15 of the tub 10may include complementary engageable surfaces 10 a, 20 a (see FIG. 2).

According to various washing appliance 1 embodiments, the tub 10 may becomprised of a variety of different metals, metallic alloys, polymers,and/or composite materials. For example, the tub 10 may be formed as asingle integral workpiece such as, for example, a stamped metal(stainless steel, for example) tub or a molded polymer tub. Furthermore,the base member 20 may, in some washing appliance 1 embodiments, beformed as a single piece and/or integral structure (i.e.,integrally-molded using materials that may include, but are not limitedto: polymers and composite materials). For example, the base member 20may be molded or otherwise constructed from a polymeric material, suchas talc-filled polypropylene. In such instances, the polymeric materialcomprising the base member 20 may be, for example, selected to absorb orotherwise reduce the transmission of sound/noise generated by theoperative components of the washing appliance 1 housed within orotherwise attached to the base member 20. As shown generally in FIGS. 1and 2, the base member 20 may comprise one or more integrally-moldedmembers or mounting structures that cooperate to support the tub 10and/or a variety of operative components of the washing appliance 1 (seeFIG. 3, for example).

In some embodiments, the base member 20 may define an open centralportion, generally designated 40, configured to, for example, receiveand support the tub 10 and/or various operative components of thewashing appliance 1 such as various controls, valves and/or pumps. Thus,the molded structure of the base member 20 may not only support the tub10, but may also provide recesses, mounting structures/surfaces, and/ormounting points for operably engaging and securing various operativecomponents of the washing appliance 1 outside the tub 10, but within theoverall structure of the washing appliance 1 (see FIG. 3, generally). Inthis manner, the tub 10 may be optimized in configuration to moreclosely correspond to the structure of the base member 20 and operativecomponent(s) secured thereby which may, in turn, help to increase oroptimize the capacity of the tub 10. As shown in FIGS. 1 and 2, the basemember 20 may define one or more engageable surfaces or mountingstructures 20 a upon which the bottom wall member 15 (and the engageablesurfaces 10 a thereof) may be supported when assembling the washingappliance 1. Such surfaces 20 a and/or mounting structures/points may beintegrally formed (molded) with the base member 20, and the bottom wallmember 15 and/or the various operative components secured thereto viaone or more fasteners and/or adhesive substances.

As shown in FIGS. 1-3, the base member 20 may include a forward end 22and a rearward end 21 (such as front and rear wall assemblies, forexample). According to such embodiments, the tub 10 may be operablyengaged with the base member 20 such that the access opening 17 definedin the tub 10 is oriented in the same direction as the forward end 22(i.e., to form a forward access opening 17). Furthermore, in suchembodiments, the complementary engageable surfaces 10 a, 20 a may bedisposed substantially adjacent to the rearward end 21 of the basemember 20. According to some embodiments, as shown generally in FIG. 2,the engageable surfaces 20 a of the base member 20 may be configuredsuch that a portion of the bottom wall member 15 defining the engageablesurface 10 a of the tub 10 may rest on and/or be supported by theengageable surface 20 a of the base member 20 when the washing appliance1 is assembled (see FIG. 3, for example).

As shown in FIGS. 2 and 3, some washing appliance 1 embodiments mayfurther comprise a support member 11 (such as a steel support frame, forexample) operably engaged with the tub 10 about the forward accessopening 17 for providing additional structural support to the washingappliance 1. Furthermore, as shown in FIG. 2, a portion 12 (such as asupport leg, for example) of the support member 11 may extend outwardlyfrom the tub 10 so as to engage the tub 10 with a portion of the basemember 20, such as about the forward end 22 thereof, wherein the portionof the base member 20 may comprise an integrally-molded attachmentstructure/point. Furthermore, in other embodiments, as shown generallyin FIG. 2, the base member 20 may define one or more support apertures23 configured to receive the portion 12 of the support member 11extending outwardly from the tub 10. In such embodiments, the insertionof the portion 12 of the support member 11 into the complementarysupport aperture 23 defined in the base member 20 may provide anadditional area of engagement/securement between the tub 10 and basemember 20 so as to augment the connection between the tub 10 and basemember 20 and facilitate the integrity of the assembly.

Referring to FIG. 1, in some embodiments, the base member 20 may beconfigured so as to define a compartment 180 about the forward endthereof, wherein the compartment 180 may be configured to receive acontrol unit or control board (not shown) implemented within the washingappliance 1 for electronically-controlling various components (i.e.,circulation pump, drain pump, water valve) in furtherance of the washingprocess. In some instances, the base member 20 is configured such thatthe compartment 180 receives a housing (not shown), in which the controlunit/board is disposed and mounted, wherein the housing may be pivotablymounted with respect to the compartment 180. In one instance, thecompartment 180 may be further configured to isolate or otherwiseprotect the control unit/board from heat and/or moisture generated bythe operative component(s) disposed within the base member 20 (which maybe beneficial, for example, for meeting certain regulatory and/or safetystandards).

In further embodiments, a catch pan member 50 may be configured tooperably engage and cover the open portion of the base member 20 fromabout the bottom side thereof. That is, the catch pan member 50 may bedisposed in opposing relationship to the bottom wall member 15 of tub 10about the opening defined by the base member 20. In such instances, thetub 10 and/or hydraulic (water-carrying) operative components of thewashing appliance 1 may be configured to engage the base member 20 suchthat any potential leakage point are disposed above or are otherwiseconfigured to drain into the catch pan member 50. In this configuration,leak detection provisions may be centralized or otherwise localized tothe catch pan member 50 (i.e., any leakage will be evident in the catchpan member 50), thereby facilitating a simpler and/or more reliable leakdetection scheme. In other instances, the catch pan member 50 and thebottom wall member 15 may further cooperate to substantially enclose theoperative component(s) disposed within the base member 20 to containnoise generated by the various operative components and reduce noiseemissions from the washing appliance 1. In some embodiments, the catchpan member 50 may be removably attached to the base member 20 such that,in instances requiring service of the washing appliance 1, the catch panmember 50 may be removed to allow or otherwise facilitate access to thevarious operative components in the base member 20. The catch pan member50 may be comprised of metals, metallic alloys, polymers, and/orcomposite materials, and, in some instances, may comprise a materialcapable of absorbing and/or blocking sound generated by the operativecomponents of the washing appliance 1.

As shown in FIG. 4, some embodiments include a lower edge of a doormember (not shown) pivotably engaged (i.e., hinged) with a lower end thetub 10 (i.e., the forward edge of the bottom wall member 15), such thatthe door member is pivotable about the lower edge thereof to provideaccess to the interior of the tub 10 through the forward access opening17, and to cover and seal the forward access opening 17 when the washingappliance 1 is in operation. In such instances, the pivotable engagementbetween the lower end of the door member and the forward edge of thebottom wall member 15 may require particular structural provisions toallow the door member to pivot as intended to an open position, whilecovering and sealing the forward access opening 17 in the closedposition. Further, appliances may often be configured to include a “toekick” space for allowing the feet of a person standing in closeproximity to the front side of the appliance to have an accommodationspace under the front side of the appliance. Accordingly, in suchinstances, the forward end 22 of the base member 20 may not extend tothe pivotable interface between the door member and the bottom wallmember 15. That is, the forward end 22 of the base member 20 may bedisposed opposite the forward edge of the bottom wall member 15 from thelower edge of the door member, so as to provide/form a toe kick recessbetween the forward end 22 and the lower edge of the door member.However, the toe kick recess formed in this manner may undesirably leaveopen or exposed portions of the base member 20, the bottom wall member15, and/or operative components disposed thereabout.

As such, aspects of the present invention may further include a covermember 60 operably engaged with the forward end 22 of the base member20, and having a flange portion 68 extending therefrom to the forwardedge of the bottom wall member 15. In some instances, the cover member68 is configured to cooperate with the base member 20 and the bottomwall member 15 so as to cover the forward end 22 of the base member 20,and the bottom wall member 15 about the toe kick recess, while extendingacross the forward edge of the bottom wall member 15 and allowing thedoor member to pivot to an open position so as to provide access to thetub 10 through the forward access opening 17. While the cover member 60is disclosed herein as being a separate component from the base member20, one skilled in the art will appreciate that, in some instances, thecover member 60 may be integrally formed with the base member 20.

In some instances, the cover member 60 may include tab portions 62 onopposing ends thereof for engaging complementary attachment mechanismstructures associated with the base member 20. For example, tab portions62 may include hook-shaped elements 64 (FIGS. 4 and 5) at the endsthereof for cooperating with projections 24 integrally-molded into thebase member 20 at opposing ends proximate the forward end 22. In thismanner, the complementary portions of the attachment mechanism mayengage each other in a slide fit, a snap fit, or in any other suitablemanner for connecting the portions of the attachment mechanism to engagethe cover member 60 with the base member 20. It is envisioned, however,that other suitable configurations may be provided for engaging thecover member 60 with the base member 20. Furthermore, the cover member60 may also include at least one foot portion 66 configured to providesupplemental engagement between the cover member 60 and the base member20, and therefore, for example, a more robust assembly. As illustratedby the hyphenated lines in FIG. 4, each foot portion 66 may beconfigured to be received by a corresponding aperture or cavity,generally designated 26, defined by the base member 20. In someembodiments, the cavity 26 may be adjacent to the support aperture 23such that foot portion 66 and portion 12 (such as a support leg, forexample) are disposed substantially adjacent to one another when thewashing appliance 1 is assembled.

Furthermore, as shown in FIGS. 4-6, the cover member 60 may include aflange portion 68 extending outwardly therefrom toward the forward edgeof the bottom wall member 15 about the lower end of the forward accessopening 17 and/or toward the lower end of the door member. As shown inFIGS. 2 and 3, in one aspect, the flange portion 68 may be configured toextend to the forward edge of the bottom wall member 15 so as tocooperate therewith to, for example, facilitate enclosure of the toekick recess and enclosure of the operative component(s) received by thebase member 20. The flange portion 68 may be further configured toextend across the forward end 22 of the base member 20 and across theforward edge of the bottom wall member 15. In this manner, the covermember 60 is configured to cooperate with the base member 20 and thebottom wall member 15 so as to cover the forward end 22 of the basemember 20 and the bottom wall member 15 about the toe kick recess, whileallowing the door member to pivot to an open position for providingaccess to the tub 10 through the forward access opening 17.

By enclosing the toe kick recess area, noise emission pathways from theappliance (of noise generated by the operative components) may beblocked, sealed, or otherwise impeded, so as to contain the noise withinthe appliance and provide, for example, the perception of a “quiet” or“quieter” appliance. In some instances, the flange portion 68 may beconfigured to cooperate with the lower end of the door member so as tonot interfere with the lower end of the door member when the door memberis pivoted to an open position (i.e., the door is not covering theforward access opening 17). In some embodiments, the cover member 60 mayfurther include a sealing member (not shown) engaged with the flangeportion 68 and extending therefrom to form a sealing engagement with theforward edge of the bottom wall member 15 and/or with the lower end ofthe door member, for example, when the door member is in a closedposition (i.e., covering the forward access opening 17 into the tub 10).The sealing member may comprise, for example, a polymeric material, suchas rubber, or any other material suitable for providing the sealingengagement.

In some embodiments, as shown in FIGS. 5 and 6, an insulation element 70may be configured to engage the cover member 60, for example, the flangeportion 68 thereof, to further facilitate containment/absorption ofnoise generated by the operative components disposed in the base member20, thereby reducing noise emissions from the appliance. The insulationelement 70 may be configured to engage the cover member 60 so as to bedisposed between the bottom wall member 15 and the flange portion 68 ofthe cover member 60. In some instances, the sound-reduction member 70may be configured to conform to the flange portion 68. The insulationelement 70 may be comprised of, for example, a sound-deadening material,such as an acoustic foam material, configured to absorb, block, orotherwise dampen the sound/noise generated by the operative componentsof the appliance disposed within the base member 20. One skilled in theart will appreciate, further, that the same or similar (or otherwiseappropriate) insulation element(s) may also be applied, in someinstances, to or about the base member 20 and/or the catch pan element50 otherwise disclosed herein. In those instances, the insulationengaged with the base member 20 and/or the catch pan element 50 mayserve to further absorb, block, or otherwise dampen the sound/noisegenerated by the operative components of the appliance disposed withinthe base member 20.

Many modifications and other embodiments of the inventions set forthherein will come to mind to one skilled in the art to which theseinventions pertain having the benefit of the teachings presented in theforegoing descriptions and the associated drawings. Therefore, it is tobe understood that the inventions are not to be limited to the specificembodiments disclosed and that modifications and other embodiments areintended to be included within the scope of the appended claims.Although specific terms are employed herein, they are used in a genericand descriptive sense only and not for purposes of limitation.

1. A washing appliance comprising: a tub having a bottom wall member anddefining a forward access opening, the bottom wall member having aforward edge and a rearward edge; a door member having a lower edgepivotably engaged with the forward edge of the bottom wall member, andbeing configured to cooperate with the tub to cover the forward accessopening; a base member configured to support the tub and extending fromabout the rearward edge of the bottom wall member toward the forwardedge thereof, the base member having a forward end disposed opposite theforward edge of the bottom wall member from the lower edge of the doormember, so as to form a toe kick recess between the lower edge and theforward end; and a cover member configured to operably engage theforward end of the base member, and having a flange portion extendingtherefrom to the forward edge of the bottom wall member, the covermember being configured to cooperate with the base member and the bottomwall member so as to cover the forward end of the base member and thebottom wall member about the toe kick recess while allowing the doormember to pivot to an open position so as to provide access to the tubthrough the forward access opening.
 2. A washing appliance according toclaim 1, wherein the base member is comprised of a molded polymericmaterial and includes at least one molded mounting structure configuredto receive the at least one operative component.
 3. A washing applianceaccording to claim 1, wherein the cover member is configured tocooperate with the base member and the tub so as to substantiallyenclose the at least one operative component.
 4. A washing applianceaccording to claim 1, wherein the base member and the cover memberrespectively define complementary portions of an attachment mechanism,the cover member thereby being securable to the base member throughengagement of the complementary portions.
 5. A washing applianceaccording to claim 1, wherein the cover member is integrally formed withthe base member.
 6. A washing appliance according to claim 1, furthercomprising an insulation element operably engaged with the cover memberand cooperable therewith to contain noise generated by the at least oneoperative component.
 7. A washing appliance according to claim 6,wherein the insulation element further comprises at least one of a soundblocking material and a sound absorbing material.
 8. A washing applianceaccording to claim 6, wherein the insulation element further comprisesan acoustic foam material.
 9. A washing appliance according to claim 1,further comprising a sealing element operably engaged with the flangeportion of the cover member, the sealing element being configured tointeract with at least one of the bottom wall member and the door memberso as to form a sealing engagement therebetween.
 10. A washing applianceaccording to claim 1, wherein the cover member is further configured tobe removable from the base member so as to allow access to the at leastone operative component disposed within the base member.
 11. A washingappliance according to claim 1, wherein at least one of the base memberand the cover member further comprises at least one of a sound blockingmaterial and a sound-absorbing material.
 12. A method of forming awashing appliance, the washing appliance including a tub having a bottomwall member and defining a forward access opening, the bottom wallmember having a forward edge and a rearward edge, a door member having alower edge pivotably engaged with the forward edge of the bottom wallmember, and being configured to cooperate with the tub to cover theforward access opening, and a base member configured to support the tuband extending from about the rearward edge of the bottom wall membertoward the forward edge thereof, the base member having a forward enddisposed opposite the forward edge of the bottom wall member from thelower edge of the door member, so as to form a toe kick recess betweenthe lower edge and the forward end, the method comprising: engaging acover member with the forward end of the base member such that a flangeportion of the cover member extends therefrom to the forward edge of thebottom wall member, the cover member being configured to cooperate withthe base member and the bottom wall member so as to cover the forwardend of the base member and the bottom wall member about the toe kickrecess while allowing the door member to pivot to an open position so asto provide access to the tub through the forward access opening.
 13. Amethod according to claim 12, further comprising molding the base memberfrom a polymeric material such that the base member includes at leastone molded mounting structure configured to receive at least oneoperative component.
 14. A method according to claim 13, whereinengaging the cover member with the forward end of the base memberfurther comprises engaging the cover member with the forward end of thebase member such that the cover member cooperates with the base memberand the tub to substantially enclose the at least one operativecomponent.
 15. A method according to claim 12, wherein the base memberand the cover member respectively define complementary portions of anattachment mechanism, and engaging the cover member with the forward endof the base member further comprises securing the cover member to theforward end of the base member by engaging the complementary portions ofthe attachment mechanism.
 16. A method according to claim 12, furthercomprising engaging an insulation element with the cover member, whereinthe insulation element is cooperable with the cover member to containnoise generated by the at least one operative component.
 17. A methodaccording to claim 16, wherein engaging an insulation element with thecover member further comprises engaging an insulation element comprisingat least one of a sound blocking material and a sound absorbing materialwith the cover member.
 18. A method according to claim 16, whereinengaging an insulation element with the cover member further comprisesengaging an insulation element comprising an acoustic foam material withthe cover member.
 19. A method according to claim 12, wherein the covermember further comprises a sealing element operably engaged with theflange portion, and engaging the cover member with the forward end ofthe base member further comprises engaging the cover member with theforward end of the base member such that the sealing element interactswith at least one of the bottom wall member and the door member to forma sealing engagement therebetween.